HOW IT CREATES A FUTURE- PROOF TYRE MANUFACTURING…

Conventional tyre manufacturing systems require too much human skill and intervention, so the impact and consequences of digitalisation on the tyre industry are even greater. Standard manufacturing processes require strict monitoring, corrections and automation at every stage. Digitalisation offers numerous benefits for sustainable production improvements. They achieve measurable results in manufacturing, quality improvement, marketing and sales.

Tyre manufacturers monitor and automate their processes, reduce manual labour and gain real-time insights into production line status and performance. Barcode and QR code labelling streamlines production processes, enables efficient and cost-effective tracking and improves accuracy and efficiency. Traceability is simple and feasible, improving profitability and customer satisfaction.

Scanning simplifies the location, tracking of parts and materials and provides manufacturers with real-time insights into their production processes. RFID applications are gaining momentum in the passenger tyre segment, having already demonstrated numerous benefits in commercial applications.

Digitalisation technologies help quick identification of production defects in the final product and increase productivity with AI based scanning, inspection, real-time decision-making processes.

Digitalisation in the tyre industry is a gradual process that will improve performance, quality and profitability being on the way of real Industry 4.0 applications in tyre manufacturing. It continually opens up new opportunities to leverage data for better decision-making. Overall, digitalisation in tyre manufacturing is a powerful tool that unlocks the full potential of production. However, after implementation, continuous investment, as well as internal research and improvements, are required.

The tyre manufacturing industry is constantly evolving. Machines are becoming increasingly automated, more precise and data-driven. Recent advances based on the principles of Industry 4.0 include the aforementioned IoT, AI (artificial intelligence), robotics and sustainability.

Industry 4.0-driven digitalisation is based on the concept of the ‘digital twin’, meaning every machine is a data node. Data from every step (compound parameters, component dimensions, curing profiles) is collected for each tyre. This creates a virtual replica of the physical tyre, which is a ‘digital twin’ that enables complete traceability and data-driven process optimisation.

The role of humans is evolving from simple manual tasks to monitoring, diagnostics and data analysis. Robots, especially collaborative robots or cobots,

are taking over tasks such as final inspection and material handling. These revolutionary steps and concepts are having a major impact on manufacturing, optimising quality, performance, customer satisfaction and contributing to business success.

Modern mixing systems are increasingly replacing conventional tangential mixers. The intermeshing of the two rotors ensures more efficient and homogeneous mixing with better temperature control. This leads to higher mixing quality and consistency.

New mixing technologies, on the other hand, utilise ‘continuous mixing systems’, i.e. the continuous and simultaneous supply of all raw materials in precisely controlled quantities. The materials are continuously mixed in a series of specialised extruders and mixing units. At the end, a continuous stream of a perfectly homogeneous mixture emerges. This represents a revolution compared to conventional batch mixing. It improves energy efficiency, reduces the carbon footprint and enables unprecedented consistency and traceability.

Highly automated ‘multi-calender systems’ are equipped with multiple rollers that can simultaneously produce multiple layers (e.g. carcass ply, squeegee layer or inner liner) with extreme precision in thickness and width. Similar to extrusion lines with laser thickness control, these systems ensure 100 percent control and transmit data immediately to the extrusion head and calender roll clearances for automatic adjustment and maintenance of tolerances down to a fraction of a millimetre.

Thanks to the ‘multi-stage transfer’, the tyre casing is transferred between drums for the various production steps automatically and without human intervention, automatic cutting and splicing prevent deviations in quality. RFID technology integrated fully assures correct recipe and security in component application.

The robotic application and component preparation, such as with 6-axis robots, is now widely used for the fast and precise gripping and placement of complex components such as bead and apex assemblies.

Electric vulcanising presses are equipped with intelligent mould controls, whose integrated sensors monitor temperature and pressure in real time across multiple zones. The AI system dynamically adjusts the vulcanisation cycle (time, temperature, steam pressure) to ensure perfect curing of each tyre and compensate for any mould or material deviations.

Furthermore, predictive maintenance is now essential to avoid unplanned production downtime. Vibration, temperature and pressure sensors installed on manufacturing machines monitor all machine functions and alert when maintenance is required. High-precision servomotors, replacing pneumatic or hydraulic systems, work with servo-electric robots and are used in various production phases with submillimetre precision, reducing energy consumption and maintenance requirements.

The most visible technological advances in finishing and inspection lines today are fully automated with full sensitive cameras, AI-integrated and non-destructive testing (NDT) machines. Automated high-resolution X-ray machines scan each tyre to detect hidden defects such as trapped air, steel cord separation, or bead wire issues. Shearography and holography – being traditional but now equipped with intuitive, incredibly fast and precise modes – use lasers and intelligence to detect underlying defects or separations by measuring stress-induced deformations.

Uniformity and force variation measurement systems utilise AI algorithms to not only identify a tyre as ‘good’ or ‘bad’ but also diagnose the root cause of the deviation. Robotic trimming and polishing machines automatically locate and remove burrs (excess rubber) from the tyre using precise grinding tools – a traditionally manual and laborious task.

Of course, the future of tyre manufacturing, driven by advanced digitalisation, IoT and robotics, is rapidly evolving into a model for a smart, autonomous and sustainable industry, often referred to as ‘Tyre Industry 4.0’.

This transformation isn’t just about doing the same things faster; it will fundamentally change tyre design, production, sales and even performance. Tyre production facilities will become more autonomous, adaptable, efficient, predictive, personalised and, as expected, more sustainable.

Industry 4.0 and AI-powered digitalisation will accelerate sustainability. Precision manufacturing minimises material waste through the use of high-precision components. AI can easily manage energy consumption throughout the factory. IoT sensors monitor the overall condition of tyres, ensuring fast tyre changes, safety and performance.

This transformation will lead to safer, more efficient and more environmentally friendly tyres.

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Pirelli has commenced 2026 by building upon its record-breaking previous year, which was distinguished by numerous victories and podium placements across its entire product portfolio and its innovative Cyber Tyre technology. This exceptional momentum is underscored by the remarkable performance of the recently launched summer Cinturato, a tyre engineered for premium sedans and CUVs that has rapidly established itself as a benchmark for safety, longevity and dynamic equilibrium. Having already secured two wins in 2025, the next-generation Cinturato has added two outright victories and three podium finishes in the opening months of 2026, excelling in six comparative tests conducted by leading European automotive publications and independent organisations.

The Cinturato's success story includes a premier position in a test by Tyre Reviews, where it was lauded as the best summer tyre of the year for its impeccable dry braking and precise steering feedback. It also achieved a triumph in evaluations by the Automobilclub von Deutschland, earning an ‘excellent’ rating and top marks in safety-critical areas like dry braking and aquaplaning resistance. Further reinforcing its technological sophistication, the tyre secured second place with a ‘Highly Recommended’ rating from the ADAC, which recognised its robust durability and diminished environmental footprint alongside its balanced handling.

Additional podium finishes came from Auto Zeitung, which praised the Cinturato as a tyre devoid of weaknesses for its safe handling and impressive mileage, and from Sweden's Vi Bilägare, which highlighted its agile nature and short stopping distances. The tyre's comprehensive capabilities were also affirmed by Auto Bild, where it progressed from a strong qualifying performance to the final round, impressing testers with its grip and balanced behaviour, especially on wet surfaces.

This outstanding beginning to the year for the Cinturato is part of a broader renewal of Pirelli's summer offerings, which recently welcomed the fifth-generation P Zero, the quintessential tyre for sports cars, and the third-generation Scorpion, the latest evolution designed to deliver safety and enduring performance for SUVs.

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Prinx Chengshan, together with its brand Chengshan, participated in the 25th Heilongjiang Agricultural Machinery Exhibition in Harbin on 14 March 2026. The event served as a platform to advance the modernisation of China’s agricultural machinery sector and foster industry exchanges. In this context, the company displayed a comprehensive range of agricultural tyres tailored for tractors and combine harvesters.

For tractors, the company presented its agricultural radial tyre series. The TX600 model is engineered with robust tread blocks and a cut-resistant compound, ensuring stable handling during high-speed operations while offering strong defence against punctures. The TX700 features a reinforced carcass and belt structure, providing significant load capacity and superior traction to perform effectively in wet and uneven fields. Meanwhile, the TX800 incorporates a deep R-1W tread pattern and a specialised wear-resistant compound, supported by strengthened beads and shoulders. This design enhances resistance to damage from straw and stones, thereby extending tyre longevity. Addressing the needs of combine harvesters, the TX2000 model delivers a 20 percent increase in load capacity and excellent flexibility. Its low-pressure, wide-footprint design minimizes soil compaction, aligning agricultural efficiency with environmental sustainability.

Additionally, the company’s bias tyre offerings, the CSY90 and CSY93, were also showcased. These tyres feature a traditional herringbone tread pattern that ensures effective self-cleaning and robust traction. They maintain reliable performance in challenging terrains such as soft sand and muddy fields, while their durable construction supports continuous operation during peak farming periods.

With the global push towards agricultural modernisation and mechanisation, Prinx Chengshan has strategically expanded its off-the-road (OTR) tyre operations. A key milestone in this effort is the newly operational green smart factory for OTR tyres. With an investment exceeding RMB 1.1 billion (approximately USD 159.50 million) and spanning over 100,000 square metres, the facility is designed to produce 84,000 engineering tyres and 10,000 giant tyres annually. Serving diverse sectors including mining, construction and agriculture, this initiative enhances the company’s high-end product portfolio and promotes the sustainable advancement of China’s OTR tyre industry.

Looking ahead, Prinx Chengshan intends to uphold its integrated product and service approach. By advancing agricultural tyre technology, the company aims to support the evolution of agricultural machinery through intelligent and sustainable solutions, contributing to the sector’s continued progress.

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Tructyre has announced the appointment of Mark Holland as its new Operations Director, effective from April 2026. In this role, he will leverage his extensive background in managing large-scale mobile service operations to enhance support for fleet customers across all sizes.

Holland transitions to Tructyre from ATS Euromaster, where he spent nearly six years as Operations Director. His tenure there also included leadership positions such as Head of Mobile Operations, Head of Network Development and Area Operations Manager. Prior to joining ATS Euromaster in 2011, he served as Network Manager at Auto Windscreens, where he was responsible for overseeing the company’s mobile teams.

In his new capacity, Holland will oversee a 350-strong fleet of service vehicles, along with tooling, equipment, supply chain and distribution. He will also manage Tructyre’s 24/7 Customer Experience Centre in Gateshead, which handles over 11,000 calls each month. Tructyre specialises exclusively in mobile servicing for trucks, trailers, buses and coaches. Its operations are supported by a network of 40 depots across England, Wales and Scotland, supplemented by additional stocking points, ensuring technicians have round-the-clock access to the necessary fitments for both planned service work and roadside emergencies.

Holland said, “Tructyre is partway through a major investment in new systems, so it’s an exciting moment to be stepping into this role. These upgrades will streamline processes for both our technicians and colleagues within our Customer Experience Centre, enabling us to deliver an even faster, more efficient service for fleets. Few industries carry the responsibility that ours does, and the opportunity to help de‑risk Britain’s commercial vehicle fleets is one I take seriously. I’m looking forward to driving operational excellence in everything we do and ensuring our customers have complete confidence in their tyres.”

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Arun Mammen, Vice Chairman and Managing Director of MRF Ltd, has been appointed to another term as Chairman of the Automotive Tyre Manufacturers' Association (ATMA). This industry body represents India's automotive tyre sector at the national level. Meanwhile, Rajarshi Moitra, Managing Director of Bridgestone India Private Limited, has assumed the role of Vice Chairman. In a separate leadership transition, Sanjay Chatterjee, formerly Assistant Director General, has been promoted to Director General of ATMA. He takes over from Rajiv Budhraja, who is set to retire on 31 March 2026.

Mammen’s educational background includes graduation from Madras Christian College and an MBA from Ashland University in United States. His professional development was significantly enhanced by extensive training with B F Goodrich Tire & Co. and Uniroyal Goodrich Tire & Co. during his time in US, an experience that proved highly beneficial in his subsequent career. He was appointed Managing Director of MRF Ltd in 2004 and later became Vice Chairman and Managing Director in 2017.

His initial tenure as ATMA Chairman began at a pivotal moment last year, coinciding with the organisation's Golden Jubilee celebrations. Established in 1975, ATMA stands as one of the country's most prominent national industry associations, representing an automotive tyre industry valued at over INR 1 trillion. The association's membership encompasses major Indian and international tyre manufacturers, who collectively account for more than 80 percent of India's total tyre production.

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